Asymmetric sectioned convex mirrors

ABSTRACT

Asymmetric sectioned mirrors are presented. The mirrors include, for example, constant radius of curvature sections that are selected to increase the sizes and improve the definitions of images, for example images of children milling, walking and/or standing about either the front or alongside regions of a school bus. The mirrors may be asymmetric in either or both the horizontal and vertical directions. The mirrors may include a mounting system capable of using both ball mounts and tunnel mounts.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalPatent Application No. 60/971,334, entitled Asymmetric Mirrors, filedSep. 11, 2007, incorporated herein by reference in its entirety.

This application is a continuation in part of, and claims the benefit ofan priority to, U.S. Pat. No. 7,517,100, entitled Asymmetric MultipleConstant Radii of Curvature Convex Mirrors, issued on Apr. 14, 2009,which claims benefit of and priority to U.S. Provisional PatentApplication No. 60/855,779 entitled Asymmetric Multiple Constant Radiiof Curvature Convex Mirrors filed Nov. 1, 2006, the entire contents ofwhich incorporated by reference herein.

BACKGROUND

This disclosure generally relates to convex, three dimensional mirrorsand, more particularly, to a mirror, sometimes referred to as a“cross-over” or “cross-view” mirror, which affords a bus driver, forexample, a school bus driver, visual access in front of, as well asalongside the bus. Such cross-over mirrors can however also be used atthe rear or front corners of other vehicles such as with trucks, mailvans and the like. More specifically, the present disclosure relates tonon-ellipsoidal, asymmetric cross-view mirrors which are optimized toproduce more distinct images of objects located in front of or alongsidea school bus or similar vehicle.

For many decades, cross-over mirrors and mirror assemblies have beendeployed on school buses, and are in fact required by federal and localregulations. A substantial body of prior art has been publisheddescribing various mirrors of the type to which the present inventionrelates. Prior art mirrors include both circular and ellipsoidalmirrors. The prior art ellipsoidal mirror lenses have been characterizedby radii of curvature (measured along planar cross-sections on the majorand minor axes) which were distinctly non-constant, i.e. tending toincrease or decrease on the mirror lens toward or adjacent itsperipheral, circumferential edge. The variation in the radius ofcurvature is used to obtain larger and less distorted images at themirror center, and smaller, but more distorted, images, at theperipheral regions on the mirror. This, in essence, would increase thefield of view that the mirror monitors in and around the school bus.

However, it has been determined that the size and general shape of themonitored area in front of a school bus, differs from that which needsto be monitored alongside the bus. That is, school buses and similarvehicles have comparative lengths several times larger than the widthsof the vehicles. The image of a child standing alongside a school busnear the rear wheels needs to be sufficiently large to afford the drivera good view of a child who may stoop low or fallen or slipped under ortoo close to the school bus. At the front of the bus, it has beendetermined, is more important to assure that the entire width andseveral feet in front of the bus are clearly visible. In other words,the field of view characteristics in front of the school bus andalongside differ from one another. Prior art mirrors have not beenoptimized to fully accommodate these differences.

Rather, all prior art mirrors, including those that have horizontallystretched bodies, are widthwise symmetrical with respect to theirgenerally vertical mounting axis. Thus, the mirror surface size andshape and field of view to the right of the axis is identical to themirror surface and view to the left of the axis. Therefore, both sidesof the lens provide the same image reflecting characteristics at theleft mirror side, which is primarily focused on the area in front of thebus, as at the right mirror side which focuses images from alongside thebus (for a mirror mounted to the right of the driver).

In addition, prior art mirrors that have varying radii of curvature overthe entire mirror surface or substantial part thereof result incontinually changing image sizes, along the surfaces of the mirror. Thiscan make it more difficult for the driver to follow and carefullymonitor the movements of a child alongside or in front of the schoolbus.

BRIEF SUMMARY

It is a feature and benefit of the present invention, in accordance withsome embodiments, to overcome the aforementioned drawbacks of the priorart and to provide a mirror, such as a cross-view mirror, whichgenerally increases the size and improves the definitions of images ofchildren milling, standing, and/or walking about either the front oralongside regions of the school bus. The features of the mirror ormirrors described below are not required, but are rather characteristicsthat may be part of the mirror, the exact features and combination ofelements being defined by the claims and not by this section of thedisclosure.

Under one aspect and/or alternative embodiment of the invention anasymmetric mirror includes multiple sections, such as a first, second,and third sections extending width wise along the mirror. The first,second, and third sections are optionally each of a different constantradius of curvature. The center section has, for example, the largestradius of curvature. In alternative embodiments, the center section hasa smaller radius of curvature at least with respect to another section.In further alternative embodiments, no specific center section isprovided, but sections that are not located at the center are utilized.

Under another aspect and/or alternative embodiment of the invention, theconstant radius of curvature sections are joined by variable radius ofcurvature sections. Under another aspect and/or alternative embodimentof the invention, only first and second sections extending width-wisealong the mirror are provided. In alternative embodiments of theinvention, the sections may have increasing and/or decreasing varyingradii of curvature.

Under another aspect and/or alternative embodiment of the invention anasymmetric mirror includes a first, second, and third sections extendingheight-wise along the mirror. The first, second, and third sections areoptionally each of a different constant radius of curvature. The centersection has the largest radius of curvature. The mirror includes first,second, and third height-wise extending sections, each respectivelyhaving a different, constant radius of curvature.

Under another aspect and/or alternative embodiment of the invention, theconstant radius of curvature height wise sections are joined by variableradius of curvature height wise sections. Under another aspect and/oralternative embodiment of the invention, only first and second sectionsextending height-wise along the mirror are provided. In alternativeembodiments of the invention, the sections may have increasing and/ordecreasing varying radii of curvature.

Under another aspect of the invention, the mirror lens is thinner in thecenter and thicker near the edge. In another alternative embodiment ofthe invention, the mirror lens is thicker in the center and thinner nearthe edge and/or has varying thickness to provide the desired effect.

Under another aspect and/or alternative embodiment of the invention anasymmetric mirror includes a first, second, and third sections extendingwidth wise along the mirror. The first and second sections have the sameradius of curvature. The third section has a different, larger, constantradius of curvature. The mirror includes at least one height-wiseextending section, such as first, second, and third height-wiseextending sections, each respectively having a different, constantradius of curvature. In alternative embodiments of the invention, anytype of mirror can be made in accordance with the present invention,including, for example, a variety of vehicle mirrors such as rear viewmirror; mirrors inside the vehicle, and/or any mirror used outside thevehicle. In addition, in alternative embodiments, the mirror lens of thepresent invention can be used in buildings, outside of buildings and inother settings that benefit from the views attainable by the mirrorlens, mounting mechanism and/or manufacturing process of the presentinvention.

Under another aspect and/or alternative embodiment of the invention themirror includes a mirror back for supporting the mirror lens and amirror mount capable of accepting a plurality of mounting mechanisms.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of various embodiments of the presentinvention, reference is now made to the following descriptions taken inconnection with the accompanying drawings in which:

FIG. 1 is a multiview orthographic projection of an asymmetric,sectioned, constant thickness mirror lens in accordance with one or moreembodiments of the invention.

FIG. 2 is a multiview orthographic projection of an asymmetric,sectioned, variable thickness mirror lens in accordance with one or moreembodiments of the invention.

FIG. 3A is a cross section view of an asymmetric constant thicknessmirror lens in accordance with one or more embodiments of the invention.

FIG. 3B is a cross section view of an asymmetric variable thicknessmirror lens in accordance with one or more embodiments of the invention.

FIG. 4 is a multiview orthographic projection of an asymmetric,sectioned, constant thickness mirror lens with a flattened top inaccordance with one or more embodiments of the invention.

FIG. 5 is a multiview orthographic projection of an asymmetric,sectioned, variable thickness mirror lens with a flattened top inaccordance with one or more embodiments of the invention.

FIG. 6 is a multiview orthographic projection of a verticallyasymmetric, sectioned, constant thickness mirror lens with a flattenedtop in accordance with one or more embodiments of the invention.

FIG. 7 is a multiview orthographic projection of a verticallyasymmetric, sectioned, variable thickness mirror lens with a flattenedtop in accordance with one or more embodiments of the invention.

FIG. 8 is a plan view showing the radii of curvature along the base ofan asymmetric mirror in accordance with one or more embodiments of theinvention.

FIGS. 9-14 are multiview orthographic projections of asymmetric,sectioned mirrors that are variations of FIGS. 4 and 5.

FIG. 15 is a plan view showing a flat top mirror in accordance with oneor more embodiments of the invention.

FIGS. 15A-15C are orthographic projections of a mirror with tintingand/or texturing in accordance with one or more embodiments of theinvention.

FIGS. 16 through 18F are illustrations of localized flattening or bowingof the outer surface of asymmetric, sectioned mirrors.

FIG. 19A and FIG. 19B are an isometric view showing a mirror lens,mirror rim, and mirror housing in accordance with one or moreembodiments of the invention.

FIG. 20A-20C are an orthographic projections of a mirror lens, mirrorrim, and mirror housing in accordance with one or more embodiments ofthe invention.

FIG. 21A is an exploded view showing a ball stud mount in accordancewith one or more embodiments of the invention.

FIG. 21B is an exploded view showing a tunnel mount in accordance withone or more embodiments of the invention.

FIG. 22 is an exploded view showing the internal structure of a mirrorhousing in accordance with one or more embodiments of the invention.

FIGS. 23 through 28B are views of a rear view mirror assembly mounted ona vehicle in accordance with one or more embodiments of the invention.

FIG. 29 is diagram of the Thermo-molding process used to manufacturemirrors in accordance with one or more embodiments of the invention.

DETAILED DESCRIPTION

Before explaining at least one embodiment of the invention in detail, itis to be understood that the invention is not limited in its applicationto the details of construction and to the arrangements of the componentsset forth in the following description or illustrated in the drawings.The invention is capable of other embodiments and of being practiced andcarried out in various ways. Also, it is to be understood that thephraseology and terminology employed herein are for the purpose ofdescription and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the invention be regarded as including equivalentconstructions to those described herein insofar as they do not departfrom the spirit and scope of the present invention.

For example, the specific sequence of the described process may bealtered so that certain processes are conducted in parallel orindependent, with other processes, to the extent that the processes arenot dependent upon each other. Thus, the specific order of stepsdescribed herein is not to be considered implying a specific sequence ofsteps to perform the process. Other alterations or modifications of theabove processes are also contemplated. For example, furtherinsubstantial approximations of the process and/or algorithms are alsoconsidered within the scope of the processes described herein.

In addition, features illustrated or described as part of one embodimentcan be used on other embodiments to yield a still further embodiment.Additionally, certain features may be interchanged with similar devicesor features not mentioned yet which perform the same or similarfunctions. It is therefore intended that such modifications andvariations are included within the totality of the present invention.

Mirror Dimensions

FIG. 1 is a multiview orthographic projection of a mirror lens 100. Themirror lens 100 includes a plurality of constant Radius of Curvature(“ROC”) surfaces 101 tailored to the viewing requirements of variousareas around the school bus. The constant ROC surfaces 101 are joined bya plurality of blending zones 102. The blending zones 102 create asmooth visual transition between the constant ROC surfaces 101.

All mirrors are manufactured within some acceptable manufacturingtolerances. These include a tolerance on how constant the radius isacross each individual ROC section, as well as a tolerance on how closethe actual ROC is to the target ROC for each individual ROC section. Forexample, deviations measured with a Coordinate Measuring Machine, on theorder of plus or minus approximately 30-thousandths (0.030) of an inchfor the radii of curvature in an individual constant ROC surface areacceptable for the purpose of this invention. In other words, if amirror surface is tested and found to have a curvature that isconsistent within 30-thousandths of an inch, the mirror surface shouldbe considered to have constant curvature, and not varying curvature. Inaddition, the ROC of an individual constant ROC surface, while constant,may deviate from the target ROC due to the manufacturing process. Forexample, a deviation on the order of plus or minus one half inch withrespect to the target value may occur in the magnitude of an individualconstant ROC surface.

The x-axis cross-section view 103 shows that the mirror lens 100 can beasymmetric along the x-axis 104. In addition, the x-axis cross-sectionview 103 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from left to right along the x-axis 104, also referred to as thehorizontal axis, the constant ROC surfaces measure 9.0, 5.0, 12.0, 5.0,and 11.0 inches, respectively. As noted above, the constant ROC surfaces101 are tailored to the viewing requirements of various areas around theschool bus. For example, the two 5.0 constant ROC surfaces 101, oneither side of the 12.0 constant ROC surface 101, allow for an expandedviewing area when compared to a mirror containing just a 12.0 constantROC surface.

The x-axis cross-section view 103 also shows the blending zones 102.There is a blending zone 102 between the 9.0 and 5.0 constant ROCsurfaces 101. Similarly, there is a blending zone 102 between the 5.0and 12.0, the 12.0 and 5.0, and the 5.0 and 11.0 constant ROC surfaces101.

The y-axis cross-section view 105 shows that the mirror lens 100 can beasymmetric along the y-axis 106. In addition, the y-axis cross-sectionview 105 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from bottom to top along the y-axis 106, also referred to as thevertical axis, the constant ROC surfaces measure 4.5, 6.5 and 5.0inches, respectively.

The x-axis cross-section view 103 and the y-axis cross-section view 105also show the thickness of the mirror lens 100. The thickness at thecenter (apex) of the lens T1 is the same as the thickness at theperimetral edge (base) T2. This is referred to as a constant wallthickness mirror lens.

FIG. 2 is a multiview orthographic projection of a mirror lens 200. Themirror lens 200 includes a plurality of constant Radius of Curvature(“ROC”) surfaces 101 tailored to the viewing requirements of variousareas around the school bus. The constant ROC surfaces 101 are joined bya plurality of blending zones 102. The blending zones 102 create asmooth visual transition between the constant ROC surfaces 101.

The x-axis cross-section view 201 shows that the mirror lens 200 can beasymmetric along the x-axis 104. In addition, the x-axis cross-sectionview 201 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from left to right along the x-axis 104, also referred to as thehorizontal axis, the constant ROC surfaces measure 9.0, 5.0, 12.0, 5.0,and 11.0 inches, respectively. As noted above, the constant ROC surfaces101 are tailored to the viewing requirements of various areas around theschool bus. For example, the two 5.0 constant ROC surfaces 101, oneither side of the 12.0 constant ROC surface 101, allow for an expandedviewing area when compared to a mirror containing just a 12.0 constantROC surface.

The x-axis cross-section view 201 also shows the blending zones 102.There is a blending zone 102 between the 9.0 and 5.0 constant ROCsurfaces 101. Similarly, there is a blending zone 102 between the 5.0and 12.0, the 12.0 and 5.0, and the 5.0 and 11.0 constant ROC surfaces101.

The y-axis cross-section view 202 shows that the mirror lens 200 can beasymmetric along the y-axis 106. In addition, the y-axis cross-sectionview 202 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror. Moving from bottom to top along they-axis 106, also referred to as the vertical axis, the constant ROCsurfaces measure 4.5, 6.5 and 5.0 inches, respectively.

The x-axis cross-section view 201 and the y-axis cross-section view 202also show the thickness of the mirror lens 200. Unlike mirror lens 100,the thickness at the center (apex) of the lens T1 is not the same as thethickness at the perimetral edge (base) T2. The outer surface of themirror lens can be adjusted to create a varying lens thickness thatincreases from the center of the lens (T1) to the perimetral edge of thelens (T2). This is referred to as a variable wall thickness mirror lens.

FIG. 3A shows an x-axis cross section view 301 of a constant thicknessmirror lens and FIG. 3B shows an x-axis cross section view 302 view of avariable wall thickness mirror lens. Cross section view 302 in FIG. 3Bshows a 12.0 inch ROC in the center section of the mirror lens, alongwith a center section lens thickness denoted as T1. This gives a 12.0+Xinch ROC for the outer surface of the center section of the mirror lens.Cross section view 302 shows the two sections of the mirror lensadjacent to the center section having a 5.0 inch ROC. However, thethickness of the mirror lens for these sections is T1+X, where X isdefined as the incremental radius and has a value greater than zero.This gives a 5.0+T1+X inch ROC for the outer surface of these sectionsof the mirror lens.

The variable wall thickness of the mirror lens is a result of adding theincremental radius X to portions of the mirror lens. This, as notedabove, results in a greater thickness (T2) at the perimetral edge. Inaddition, the variable wall thickness results in the inner and outersurfaces of the lens no longer being parallel. Snell's law states thatthe non-parallel inner and outer surfaces create a slight doubling(refraction) of the image, that will still overlap the original image.This gives the appearance that resulting image is wider than theoriginal image. This can, for example, make the images of children infront of a bus larger and more easily recognized. This can also make theimage width better for FMVS111 and CMVS111, incorporated herein byreference. Both standards have image width requirements for images seennear the edge of the field of view.

In an alternative embodiment of the invention, the mirror lens isthicker in the center and thinner near the edge. The choice of mirrorthickness is a design choice used to provide the desired image effect inthe region of interest for the particular mirror application.

FIG. 4 is a multiview orthographic projection of a mirror lens 400. Themirror lens 400 includes a plurality of constant Radius of Curvature(“ROC”) surfaces 101 tailored to the viewing requirements of variousareas around the school bus. The constant ROC surfaces 101 are joined bya plurality of blending zones 102. The blending zones 102 create asmooth visual transition between the constant ROC surfaces 101.

The x-axis cross-section view 401 shows that the mirror lens 400 can beasymmetric along the x-axis 104. In addition, the x-axis cross-sectionview 401 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from left to right along the x-axis 104, also referred to as thehorizontal axis, the constant ROC surfaces measure 9.0, 5.0, 12.0, 5.0,and 11.0 inches, respectively. As noted above, the constant ROC surfaces101 are tailored to the viewing requirements of various areas around theschool bus. For example, the two 5.0 constant ROC surfaces 101, oneither side of the 12.0 constant ROC surface 101, allow for an expandedviewing area when compared to a mirror containing just a 12.0 constantROC surface.

The x-axis cross-section view 401 also shows the blending zones 102.There is a blending zone 102 between the 9.0 and 5.0 constant ROCsurfaces 101. Similarly, there is a blending zone 102 between the 5.0and 12.0, the 12.0 and 5.0, and the 5.0 and 11.0 constant ROC surfaces101.

The y-axis cross-section view 402 shows that the mirror lens 400 can beasymmetric along the y-axis 106. In addition, the y-axis cross-sectionview 402 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from bottom to top along the y-axis 106, also referred to as thevertical axis, the constant ROC surfaces measure 4.5, 6.5 and 2.0inches, respectively.

The x-axis cross-section view 401 and the y-axis cross-section view 402show that mirror lens 400 is a constant wall thickness mirror lens.

Unlike mirror lens 100 of FIG. 1, the top of mirror lens 400 isflattened. One advantage of this shape is that it reduces the size, orfootprint, of the mirror without reducing the field of view of themirror. The decreased footprint of the mirror reduces the size of theforward looking blind spot of the mirror in front of the vehicle. Inaddition, the mirror's aerodynamic performance is improved whilereducing the mirror weight and cost of mounting the mirror to thevehicle. In the alternative, the footprint of the mirror may bemaintained while obtaining the benefit of increased image sizes.

FIG. 5 is a multiview orthographic projection of a mirror lens 500. Themirror lens 500 includes a plurality of constant Radius of Curvature(“ROC”) surfaces 101 tailored to the viewing requirements of variousareas around the school bus. The constant ROC surfaces 101 are joined bya plurality of blending zones 102. The blending zones 102 create asmooth visual transition between the constant ROC surfaces 101.

The x-axis cross-section view 501 shows that the mirror lens 500 can beasymmetric along the x-axis 104. In addition, the x-axis cross-sectionview 501 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from left to right along the x-axis 104, also referred to as thehorizontal axis, the constant ROC surfaces measure 9.0, 5.0, 12.0, 5.0,and 11.0 inches, respectively. As noted above, the constant ROC surfaces101 are tailored to the viewing requirements of various areas around theschool bus. For example, the two 5.0 constant ROC surfaces 101, oneither side of the 12.0 constant ROC surface 101, allow for an expandedviewing area when compared to a mirror containing just a 12.0 constantROC surface.

The x-axis cross-section view 501 also shows the blending zones 102.There is a blending zone 102 between the 9.0 and 5.0 constant ROCsurfaces 101. Similarly, there is a blending zone 102 between the 5.0and 12.0, the 12.0 and 5.0, and the 5.0 and 11.0 constant ROC surfaces101.

The y-axis cross-section view 502 shows that the mirror lens 500 can beasymmetric along the y-axis 106. In addition, the y-axis cross-sectionview 502 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror. Moving from bottom to top along they-axis 106, also referred to as the vertical axis, the constant ROCsurfaces measure 4.5, 6.5 and 2.0 inches, respectively.

The x-axis cross-section view 501 and the y-axis cross-section view 502show that mirror lens 500 is a variable wall thickness mirror lens. Theadvantages of a variable wall thickness mirror lens are discussed abovewith respect to FIG. 2.

Unlike mirror lens 100 of FIG. 1, the top of mirror lens 500 isflattened. The advantages of this flattened shape are discussed abovewith respect to FIG. 4.

FIG. 6 is a multiview orthographic projection of a mirror lens 600.

Unlike the mirror lens 100 of FIG. 1, the x-axis cross-section view 601shows that the mirror lens 600 is symmetric along the x-axis 104. Mirrorlens 600 has constant ROC surface measuring 9.0 inches along the x-axis.

The y-axis cross-section view 602 shows that the mirror lens 600 can beasymmetric along the y-axis 106. In addition, the y-axis cross-sectionview 602 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from bottom to top along the y-axis 106, also referred to as thevertical axis, the constant ROC surfaces measure 4.5, 6.5 and 1.0inches, respectively.

The x-axis cross-section view 601 and the y-axis cross-section view 602show that mirror lens 600 is a constant wall thickness mirror lens.

Unlike mirror lens 100 of FIG. 1, the top of mirror lens 600 isflattened.

The advantages of this flattened shape are discussed above with respectto FIG. 4.

FIG. 7 is a multiview orthographic projection of a mirror lens 700.

Unlike the mirror lens 100 of FIG. 1, the x-axis cross-section view 701shows that the mirror lens 700 is symmetric along the x-axis 104. Mirrorlens 700 has constant ROC surface measuring 9.0 inches along the x-axis.

The y-axis cross-section view 702 shows that the mirror lens 700 can beasymmetric along the y-axis 106. In addition, the y-axis cross-sectionview 702 shows that the ROC at the center of the mirror is larger thanthe ROC at the edge of the mirror.

Moving from bottom to top along the y-axis 106, also referred to as thevertical axis, the constant ROC surfaces measure 4.5, 6.5 and 1.0inches, respectively.

The x-axis cross-section view 701 and the y-axis cross-section view 702show that mirror lens 700 is a variable wall thickness mirror lens. Theadvantages of a variable wall thickness mirror lens are discussed abovewith respect to FIG. 2.

Unlike mirror lens 100 of FIG. 1, the top of mirror lens 700 isflattened.

The advantages of this flattened shape are discussed above with respectto FIG. 4.

FIG. 8 is a plan view of mirror lens 800. This shows that the perimetraledge of the mirror can include as many as 13 or more distinct ROC's.

FIGS. 9 and 10 illustrate variations of FIGS. 4 and 5 where there is amore abrupt transition from vertical to horizontal at the top of themirror.

FIG. 9 is a multiview orthographic projection of a mirror lens 900. Themirror lens 900 is similar to the mirror lens 400 of FIG. 4. The x-axiscross-section view 901 shows that the mirror lens 900 can be asymmetricalong the x-axis 104. Moving from left to right along the x-axis 104,also referred to as the horizontal axis, the constant ROC surfacesmeasure 9.0, 5.0, 12.0, 5.0, and 11.0 inches, respectively. The y-axiscross-section view 902 shows that the mirror lens 900 can be asymmetricalong the y-axis 106. Moving from bottom to top along the y-axis 106,also referred to as the vertical axis, the constant ROC surfaces measure4.5, 6.5 and 0.5 inches, respectively. The x-axis cross-section view 901and the y-axis cross-section view 902 show that mirror lens 900 is aconstant wall thickness mirror lens.

FIG. 10 is a multiview orthographic projection of a mirror lens 1000.The mirror lens 1000 is similar to the mirror lens 500 of FIG. 5. Thex-axis cross-section view 1001 shows that the mirror lens 1000 can beasymmetric along the x-axis 104. Moving from left to right along thex-axis 104, also referred to as the horizontal axis, the constant ROCsurfaces measure 9.0, 5.0, 12.0, 5.0, and 11.0 inches, respectively. They-axis cross-section view 1002 shows that the mirror lens 1000 can beasymmetric along the y-axis 106. Moving from bottom to top along they-axis 106, also referred to as the vertical axis, the constant ROCsurfaces measure 4.5, 6.5 and 0.5 inches, respectively. The x-axiscross-section view 1001 and the y-axis cross-section view 1002 show thatmirror lens 1000 is a variable wall thickness mirror lens. Theadvantages of a variable wall thickness mirror lens are discussed abovewith respect to FIG. 2.

FIGS. 11 and 12 illustrate additional variations of FIGS. 4 and 5 wherethe asymmetry along the x-axis has been reduced and there is a moreabrupt transition from vertical to horizontal at the top of the mirror.

FIG. 11 is a multiview orthographic projection of a mirror lens 1100.The mirror lens 1100 is similar to the mirror lens 400 of FIG. 4. Thex-axis cross-section view 1101 shows that the mirror lens 1100 can beasymmetric along the x-axis 104. Moving from left to right along thex-axis 104, also referred to as the horizontal axis, the constant ROCsurfaces measure 10.0, 5.0, 12.0, 5.0, and 11.0 inches, respectively.The y-axis cross-section view 1102 shows that the mirror lens 1100 canbe asymmetric along the y-axis 106. Moving from bottom to top along they-axis 106, also referred to as the vertical axis, the constant ROCsurfaces measure 4.5, 6.5 and 1.0 inches, respectively. The x-axiscross-section view 1101 and the y-axis cross-section view 1102 show thatmirror lens 1000 is a constant wall thickness mirror lens.

FIG. 12 is a multiview orthographic projection of a mirror lens 1200.The mirror lens 1200 is similar to the mirror lens 500 of FIG. 5. Thex-axis cross-section view 1201 shows that the mirror lens 1200 can beasymmetric along the x-axis 104. Moving from left to right along thex-axis 104, also referred to as the horizontal axis, the constant ROCsurfaces measure 10.0, 5.0, 12.0, 5.0, and 11.0 inches, respectively.The y-axis cross-section view 1202 shows that the mirror lens 1200 canbe asymmetric along the y-axis 106. Moving from bottom to top along they-axis 106, also referred to as the vertical axis, the constant ROCsurfaces measure 4.5, 6.5 and 1.0 inches, respectively. The x-axiscross-section view 1201 and the y-axis cross-section view 1202 show thatmirror lens 1200 is a variable wall thickness mirror lens. Theadvantages of a variable wall thickness mirror lens are discussed abovewith respect to FIG. 2.

FIGS. 13 and 14 illustrate additional variations of FIGS. 4 and 5 wherethe mirror is symmetric along the x-axis and there is a more abrupttransition from vertical to horizontal at the top of the mirror.

FIG. 13 is a multiview orthographic projection of a mirror lens 1300.The mirror lens 1300 is similar to the mirror lens 400 of FIG. 4. Thex-axis cross-section view 1301 shows that the mirror lens 1300 can besymmetric along the x-axis 104. Moving from left to right along thex-axis 104, also referred to as the horizontal axis, the constant ROCsurfaces measure 11.0, 5.0, 12.0, 5.0, and 11.0 inches, respectively.The y-axis cross-section view 1302 shows that the mirror lens 1300 canbe asymmetric along the y-axis 106. Moving from bottom to top along they-axis 106, also referred to as the vertical axis, the constant ROCsurfaces measure 4.5, 6.5 and 1.0 inches, respectively. The x-axiscross-section view 1301 and the y-axis cross-section view 1302 show thatmirror lens 1300 is a constant wall thickness mirror lens.

FIG. 14 is a multiview orthographic projection of a mirror lens 1400.The mirror lens 1400 is similar to the mirror lens 500 of FIG. 5. Thex-axis cross-section view 1401 shows that the mirror lens 1400 can besymmetric along the x-axis 104. Moving from left to right along thex-axis 104, also referred to as the horizontal axis, the constant ROCsurfaces measure 11.0, 5.0, 12.0, 5.0, and 11.0 inches, respectively.The y-axis cross-section view 1402 shows that the mirror lens 1400 canbe asymmetric along the y-axis 106. Moving from bottom to top along they-axis 106, also referred to as the vertical axis, the constant ROCsurfaces measure 4.5, 6.5 and 1.0 inches, respectively. The x-axiscross-section view 1401 and the y-axis cross-section view 1402 show thatmirror lens 1400 is a variable wall thickness mirror lens. Theadvantages of a variable wall thickness mirror lens are discussed abovewith respect to FIG. 2.

FIG. 15 is a plan view of mirror lens 1500. This figure shows that thetop perimetral edge of the mirror can be completely flat.

FIGS. 15A-C are a multiview orthographic projection of a mirror lens1500. Like previously described lenses, the mirror lens 1500 depicted inFIG. 15A, FIG. 15B and FIG. 15C is asymmetric along the y-axis. Unlikepreviously described lenses, the top lens section along the y-axis istreated with a dark tint 1501. The overall shape of this tinting allowsinstant visual aligning of the mirror by being able to generally notethe size of the tinting along the y-axis. In addition, the shape of thetinting generally covers areas on the mirror which show the horizonaround the bus and the center of the bus itself, where obviouslychildren will not be seen, as can be appreciated by viewing the imagesin FIGS. 25 through 28. The tinting also reduces glare. The dark tintsection 1501 can be any non-reflective surface. During manufacturing,the entire mirror lens is generally covered with the mirror surface.Then, as an additional manufacturing step, the tinting layer is appliedto the top section of the mirror.

In another embodiment, the top section of mirror lens 1500 may beopaque, not tinted. During manufacturing, the top section of the lens ismasked off prior to the application of the reflective layer. After themirror layer is applied, the top section of the lens is transparent.Then, as an additional step, the interior of the top section of themirror is coated with an opaque layer, such as grey paint.

In another embodiment, the top section of mirror lens 1500 may betextured, not tinted. During manufacturing, the top section of the lensis masked off prior to the application of the reflective layer. Afterthe mirror layer is applied, the top section of the lens is transparent.Then, as an additional step, exterior of the top portion of the mirroris textured. The textured surface, like the tint above, prevents glareas the top section of the mirror lens is no longer smooth. The texturedsurface may also be used in combination with tinting or the applicationof an opaque layer.

The texturing of the lens surface can occur either during the forming ofthe mirror lens or after the lens is formed. For example, an optionalmethod the forming of the lens is Thermo-molding, discussed in moredetail below. Using the Thermo-molding process a mold is machined andsurfaced. The portion of the mold used to form the textured surface ofthe mirror lens can be constructed of a non-smooth surface.Alternatively, injection molding which also uses a machined mold may beused for form the mirror lens. The use of a mold to form the texturedsurface of the lens reduces the number of steps, and cost, tomanufacture the mirror lens.

FIGS. 16 through 18F show that localized flattening or bowing of theouter surface can be used to create unique magnification in an area onthe lens to improve viewing of an image in that zone.

In further embodiments of the invention, the radii of curvaturearrangement on the mirror lens can be reversed relative to the y-axis,to create a lens for the left side of the school bus, nearer the driver.That is, in the lenses previously described, images of a person standingin front of the bus are seen on the left side of the mirror and thosestanding alongside of the bus appear in the right hand side of themirror. For a comparable lens placed on the left side of the bus, thelocations of the persons would be reversed and, therefore, so are themirror's different radii of curvature sections. For example, thereversed version of the mirror lens 100 of FIG. 1 would have constantROC surfaces that measure 11.0, 5.0, 12.0, 5.0, and 9.0 inches, movingfrom left to right along the x-axis 104.

In further embodiments of the invention, optionally there may beblending zones between the constant ROC surfaces along the verticalaxis. In further embodiments of the invention, optionally there may bevariations in the blending zones 102 that create a smooth visualtransition between the constant ROC surfaces 101. The blending zone 102may include a step-wise transition, a linear transition, or a morecomplex curve, between the constant ROC surfaces 101. For example, inFIG. 1, the blending zone 102 between the 9.0 and 5.0 inch constant ROCsurfaces 101 could include a step-wise transition. The step-wisetransition could be made up of a plurality of constant and/or varyingsurfaces, such as three constant ROC surfaces of 8.0, 7.0. and 6.0inches. Alternatively, the blending zone 102 between the 9.0 and 5.0inch constant ROC surfaces 101 could include linear transition betweenthe 9.0 and 5.0 inch constant ROC surfaces 101. In addition, theblending zone 102 between the 9.0 and 5.0 inch constant ROC surfaces 101could include a quadratic or other higher order transition.

In further embodiments of the invention, there may also be variations inthe constant ROC surfaces 101. The ROC surfaces 101 may include,partially or completely, varying ROCs including one or both ofincreasing and decreasing ROCs. The varying ROC surfaces may include astep-wise transition, a linear transition, and/or a more complex curve,between the blending zones 102, and may include any combination ofincreasing and decreasing varying radii of curvature.

In further embodiments of the invention, the center section of themirror no longer has the largest radius of curvature. For example, amirror lens similar to the mirror lens 100 could be constructed withconstant ROC sections that measure 9.0, 8.0, 5.0, 10.0, and 11.0 inches,respectively. Moving from bottom to top along the y-axis of the mirrorthe constant ROC surfaces measure 4.5, 6.5 and 5.0 inches, respectively.The mirror lens may include a constant or varying lens thickness asdescribed in FIG. 3 above. In addition, as described above, the mirrorcould consist of a mix of varying ROC sections and/or constant ROCsections, where the center section of the mirror no longer has thelargest ROC.

Mirror Mounting—Generally

FIG. 19A and FIG. 19B are an isometric view of an exemplary mirror lens1900, a mirror housing 1901, and a mirror rim 1902 in accordance with analternative embodiment of the present invention that may optionally beused in combination with the mirror lens described above. The perimetraledge of the mirror lens 1900 is sized to fit within the mirror housing1901. The mirror lens 1900 is secured between the mirror housing 1901mirror rim 1902 with screws or other connectors.

The mirror rim 1902 is optionally thickest along the top and bottom ofthe mirror. However, along the sides of the mirror, the mirror rim 1902is advantageously thinner in order to maximize the reflective mirrorsurface in the horizontal direction. The additional horizontal viewingarea improves the ability of the driver to see images of childrenmilling, walking, and/or standing about alongside regions of the schoolbus. In an alternative embodiment, the mirror rim is thinned along thebase of the mirror. This provides and expanded viewing area below themirror, for example, in front of the bus.

FIGS. 20A, 20B, and 20C are collectively an multiview orthographicprojection of an exemplary mirror lens 2000, a mirror housing 2001, anda mirror rim 2002 in accordance with alternative embodiments of theinvention. The mirror lens 2000 is secured between the mirror housing2001 mirror rim 2002 with screws or other connectors.

FIGS. 21A and 21B are an exploded view of an exemplary mirror lens 2100,a mirror housing 2101, and a mirror rim 2102. Again, the mirror lens2100 is secured between the mirror housing 2101 mirror rim 2102 withscrews or other connectors. The rear of the mirror housing 2101 includessupport ribs 2103 and a spherical socket 2104. This allows for at leasttwo different methods (tunnel as shown in FIG. 21A or ball stud as shownin FIG. 21B) of mounting the mirror assembly to the school bus or othervehicle. This reduces the cost of producing and stocking mirrors, asonly a single mirror housing 2101 needs to be produced for customersthat use either type of mirror mount.

With reference to FIG. 21A, when a tunnel mount is optionally used, atubular mounting arm 2105 is located along the internal support ribs2102. The mirror housing 2101 is secured to the mounting arm 2105 by atunnel mount cover 2106. The tunnel mount cover 2106 includes additionalsupport ribs 2103 to hold the mounting arm 2105 securely in place.

With reference to FIG. 21B, when a ball stud mount is optionally used, aball stud 2107 is placed in the spherical socket 2104. The ball stud issecured in place using a ball stud mount cover 2108. The stud portion ofthe ball stud protrudes through an opening in the ball stud mount cover2108 and through an opening in the mounting arm 2109. A nut holds theball stud 2107, the ball stud mount cover 2108, and the mounting arm2109 together. The mounting arm 2109 may be located between the mirrorhousing 2101 and the ball stud mount cover 2108. In the alternative, theball stud mount cover 2108 may be located between the mirror housing2101 and the mounting arm 2109.

FIG. 22 is a cutaway view of an exemplary mirror housing 2200 inaccordance with alternative embodiments of the present invention. Therear of the mirror housing 2200 again includes support ribs 2201 and aspherical socket 2202. The interior of the mirror housing 2200 is alsoshown. The interior of the mirror housing 2200 includes mounting screwholes 2203, rim screw holes 2204, and support ribs 2205. The mountingscrew holes 2203 are used to engage the screws holding the mirrorhousing 2200 to the mounting arms, as discussed in FIG. 21. The rimscrew holes 2204 are used to engage the screws holding the mirrorhousing 2200 to the mirror rim, as discussed in FIGS. 20A, 20B, and 20C.

The support ribs 2205 allow for a thinner mirror housing section whichdecreases both the weight and manufacturing cost of the mirror housing2200, while maintaining and/or increasing the housing strength. Thesupport ribs 2205 are used to maintain the shape of the mirror housing2200 while under load, such as wind loads while the vehicle is moving orwhile the mirror is being adjusted on the mirror mount. The support ribsare sized for the expected load. For example, the support ribs 2205adjacent to the mounting area are larger to maintain the structuralintegrity of the mirror housing. The support ribs 2205 along the top andsides of the mirror housing 2200 are smaller as the loads the dynamicloads are less in these areas. The smaller support ribs 2205 in theseareas, again allow for reduced weight and manufacturing cost of themirror housing 2200.

FIG. 23A, FIG. 23B, and FIG. 23C are a perspective views of an exemplarymirror housing 2300 in accordance with an optional embodiment of thepresent invention. Unlike, the mirror housing 2101 of FIG. 21A or FIG.21B, mirror housing 2300 has an angular cutout that allows the mirrorhousing to be mounted on a non vertical mounting arm 2301.

FIG. 24A, FIG. 24B and FIG. 24B are an exploded views of an exemplarymirror housing 2400, mounting arm 2401, and various mounts. FIG. 24Ashows a non vertical mounting arm 2401 that passes through the angularcutout in mirror housing 2400. The non vertical mounting arm 2401 issecured in the angular cutout by bracket 2402. The placement of themirror housing 2401 can be adjusted in both translation and rotationaround the axis of the non vertical mounting arm 2401.

FIG. 24B shows the non vertical mounting arm 2401 secured in the angularcutout by screw-clamp 2403. The screw-clamp 2403, like the bracket above2402, allows for the mirror housing 2400 to be adjusted in bothtranslation and rotation around the axis of the non vertical mountingarm 2401. However, the mirror housing 2400 can also be rotated in anadditional dimension, around the axis of the screw holding the mirrorhousing 2400 and the screw-clamp 2403 together.

FIG. 24C shows the non vertical mounting arm 2401 secured in the angularcutout by ball-clamp 2404. The ball-clamp, like the bracket above,allows for the mirror housing 2400 to be adjusted in both translationand rotation around the axis of the non vertical mounting arm 2401. Theball-clamp 2404, unlike like the screw-clamp 2403 above, allows for themirror housing 2400 to be adjusted in three axes of rotation around theball joint.

The interior (not shown) of the mirror housing 2400 of FIG. 24A, FIG.24B and FIG. 24C is similar to interior of the mirror housing 2200 ofFIG. 22A. The interior includes mounting screw holes, rim screw holes,and support ribs. The mounting screw holes are used to engage the screwsholding the mirror housing to the mounting bracket 2402 or screw-clamp2403. The rim screw holes are used to engage the screws holding themirror housing to the mirror rim, as discussed in FIG. 20. In addition,the mirror housing 2400 may include a spherical socket to engage aball-bracket mount 2404. As discussed in FIG. 22, this allows formultiple methods of mounting the mirror assembly to the school bus orother vehicle. This reduces the cost of producing and stocking mirrors,as only a single mirror housing 2101 needs to be produced for customersthat use either type of mirror mount.

FIGS. 25A and 25B and 27A and 27B are perspective views of a rear viewmirror assembly with an included cross view mirror. It will be apparentthat any of the aforementioned mirrors can be used for either the rearview mirror assembly and cross view mirror, and any of the abovedescribed mirror mounts may optionally be used.

FIGS. 26A and 26B and 28A and 28B are views of a rearview mirrorassembly with an included cross view mirror displayed from the view ofthe user (e.g., a driver's eye point view). It will be apparent that anyof the aforementioned mirrors can be used for either the rear viewmirror assembly and cross view mirror.

Mirror Manufacturing—Generally

One method of forming mirror sectioned mirrors is injection molding.This process allows the production of a part, in this case a mirror,which reproduced precisely the contours of a three dimensional designthat were machined into a mold. The use of a machined mold allows forthe production of complex mirror shapes where sections of the mirrorhave different optical characteristics. In addition the mold can betextured and the texture will be reproduced on the finished part.Finally, during the cooling of the molten plastic, the mirror willshrink. The mold can be proportionally sized to account for thisshrinkage so that the finished part meets the design tolerances.

Referring to FIG. 29, an optional method for standard Thermo-molding isillustratively displayed. The Thermo-molding process is an alternativemethod that may be used to manufacture the mirror lens of the presentinvention. The Thermo-molding manufacturing process gives the ability toproduce arbitrary three-dimensional shapes from plastic sheets 2901, andpreserves the optical integrity of the sheets in accordance with themirror lens configurations described above. The resultingthree-dimensional shapes are suitable for mirrors, reflectors, signs,camera domes, and other optically sensitive applications. Thethree-dimensional shapes can be defined using standard three dimensionalCAD software. Furthermore, since the process is based on thermallymolding parts starting from an initially flat sheet 2901, the toolingcan be much lower cost than would be the case if a person tried toinjection mold a similar part. Even if an injection molded part could bemade to be dimensionally similar to the thermo-molded part, thethermo-molded part may have the additional advantages of better adhesionbetween the plastic and the metallization, and less distortion or otherblemishes in the final product. This can provide higher quality productwith better durability. The process can also permit the production offewer parts at a reasonable cost per part, because, for example, theinitial huge start-up cost of creating an injection molding tool isrendered unnecessary.

The steps in the Thermo Molding process may include: Construction/designof tooling; selection of raw materials; heating, shaping, and coolingthe part; and finishing the part, as described below.

Mirror Manufacturing—Tooling

In one embodiment of the manufacturing process of the present invention,the tooling consists primarily of a machined block 2302 of porousaluminum, such as MetaPore. The block can be machined using CAD/CAMsoftware to produce any three dimensional shape desired. In someinstances, undercuts may not be able to be produced using thistechnique. After machining, the block can be polished to a high polishusing, for example, progressively finer and finer grit sand paper. Theblock is fitted to a vacuum apparatus (e.g., a vacuum pump, vacuum box,roughing pump, drag pump, etc.) so that air may be drawn through theporous block, sucking the heated plastic sheet against the block,causing it to conform very precisely to the block. The block can includetemperature control. For example, the block can be fitted with copperwater tubes for precise uniform temperature control.

For a second surface convex mirror, a female tool can be used. For asecond surface concave mirror, a male tool can be used. Just theopposite would be the case for first surface mirrors. The tooling can beconstructed so that the metallization (e.g., the later applied layer tomake the mirror reflective) can be applied to the surface that does notcome into contact with the mold. This can be important because there canbe some very slight tool mark-off, and it is preferred that the markingsoccur on the surface opposite the metallization.

Mirror Manufacturing—Raw Materials

Optical quality sheet stock can be used to achieve a finished part withoptical quality sufficient for a mirror. For example, both CyroIndustries and Plaskolite make such “mirror grade” sheet stock at thistime from extruded acrylic. It will be apparent that the invention isnot limited to materials from these two vendors. Tests have successfullydemonstrated parts thermo-molded with polycarbonate sheet. High qualitysheet stock is also required as the thermo-molding process does noteliminate any defects in the sheet stock generated during the originalsheet manufacturing process.

There can be a preference for sheets supplied with heat applied (e.g.,with no residue leaving adhesives) poly masking (e.g., 2-3 mil thick) onboth sides. The poly mask protects the surface integrity during shippingand handling. Furthermore, during forming, the use of the poly maskprevents the underlying sheet stock from coming in contact with themachined block 2902. With acrylics, this can work extremely well, andany tiny mold mark-off can be absorbed in the poly mask. When the polymask is stripped off and disposed of, the mold mark-off can disappearwith it leaving a pristine, optical quality, surface. However, withpolycarbonate sheet stock the poly mask must stripped from both sides ofthe sheet prior to forming because the required forming temperature canbe too high for the poly mask.

Mirror Manufacturing—Heating, Shaping, and Cooling

The sheet can be clamped 2303 in a frame above the mold and heat 2304can be applied from one side only. The heat is generally applied to theside of the sheet stock that is not going to be in contact with themold. This permits the side of the sheet stock that is in contact withthe mold to be a bit cooler. This allows the sheet stock to be hotenough to be formed to the desired three dimensional shape, whilereducing the tooling mark-off on the cooler side of the sheet.

The part is shaped by pulling vacuum 2305 through the porous metal mold2302, sucking the sheet stock against the mold 2303 for final dimensionsas well as for cooling. This can be important because with millions oftiny vacuum holes, the amount of air extracted can be roughly equal overthe entire surface of the mold. Some thermoforming molds are made withsolid aluminum which can be fabricated by drilling lots of little holesin solid aluminum molds. These drilled vacuum holes can produce smalloptical defects at the location of the drilled hole. These defects maybe due to the air movement in the vicinity of the vacuum hole inaddition to the fact that the plastic must literally bridge the hole. Inmirrors and other optically sensitive parts, this can produce unsightlydefects in the finished product. The porous metal tool 2302 used inthermo-molding can produce negligible such defects since there can bemillions of microscopic holes over the entire surface of the mold.

Temperature control of the mold is important. The mold should be hotenough to permit the part to accurately conform to the molddimensionally, but below the glass transition temperature of the polymerforming the sheet stock. The mold temperature can be controlled bypassing controlled temperature water through the mold's 2302 watertubes. This way when the hot sheet stock contacts the mold, it can begincooling from such contact, but not too fast. Furthermore, once thevacuum process is started so as to shape the part, the heat source 2304can be removed and a fan 2306 can blow room temperature air across theback side, thereby providing uniform cooling from both sides of thepart. Plastic can shrink when it cools from forming temperature to roomtemperature, and if not for the vacuum holding the part and for the polyfilm mask, when the part shrinks it can create thousands of tinyscratches and blemishes in the surface of the part. Negligible blemishesoccur in thermo-molding because the vacuum 2305 holds the part securelyagainst the mold 2302 during cooling. In addition the poly mask absorbsany tiny mark off and does not transmit those defects on to the finishedpart surface. The end result is that, when the part is cooled back toroom temperature and the poly mask is stripped off, the part can have asubstantially untarnished (e.g., pristine) surface suitable for mirrorsor other optically sensitive applications.

Mirror Manufacturing—Finishing

After demolding, if manufacturing a mirror, the part can be vacuummetallized to become reflective. It can be important to note that with athermo-molded part, the adhesion between the deposited metal and theplastic is substantially better than other methods. This is because thesurface being metallized can be protected with poly mask until justprior to thermo-molding. Even after thermo-molding the sheet stock mayhave never touched anything but hot or cold air until the metal can bedeposited. So the metallized side can be substantially untarnished(e.g., pristine) as well as the side that contacted the mold, resultingin a substantially better finished mirror or other part. Aftermetallization the part is typically back-coated to protect themetallization, and trimmed to final outer dimensions.

Again referring to FIG. 29, the basic components of the thermo-moldapparatus is illustratively displayed. In some instance, the vacuumapparatus (e.g., vacuum box) 2305 can be constructed to be large enoughto define in the mold block 2302 several molding cavities, for thesimultaneous fabrication of multiple parts. For example, forconstructing multiple convex mirrors described above. In otherinstances, separate mold blocks can be provided in the vacuum box forcreating each mold cavity (e.g., to attain reduced costs, easierservicing, repair and/or for better individualized control andregulation of the fabrication of each part in the same vacuum box,etc.).

While the invention has been described with reference to specificembodiments, the description is illustrative of the invention and in notto be construed as limiting. While discussed with respect to mirrormounted on a school bus, the invention can be utilized for a multitudeof purposes (e.g., trucks, cars, tanks, and any other opticalapparatus). Further, it is understood that the word mirror refers to anyoptical apparatus such as mirrors, reflectors, signs, camera domes, andother optically sensitive devices.

The invention claimed is:
 1. An asymmetric mirror comprising: a convexmirror lens having a periphery which defines at least one substantiallywidth-wise extending axis and at least one substantially height-wiseextending axis, a plurality of mirror lens sections of constant radiusof curvature arranged at least width-wise along the mirror lens, saidplurality of mirror lens sections including: a first mirror lens sectionhaving a first constant radius of curvature, located to one siderelative to the height-wise axis of the mirror lens; a second mirrorlens section having a second constant radius of curvature which isdifferent from the first radius of curvature, located to the other sideof the height-wise extending axis of the mirror lens; and a third mirrorlens section having a third radius of curvature and located between thefirst and second mirror lens sections and occupying at least part of amiddle section of the mirror lens where an intersection of thewidth-wise extending axis and height-wise extending axis is located; andwherein the third radius of curvature is a constant radius of curvature,which is larger than the first and second radius of curvature, andwherein the mirror lens is thicker in the first and second mirror lenssections and thinner in the third mirror lens section.
 2. An asymmetricmirror comprising: a convex mirror lens having a periphery which definesat least one substantially width-wise extending axis and at least onesubstantially height-wise extending axis, a plurality of mirror lenssections of constant radius of curvature arranged at least height-wisealong the mirror lens, said plurality of mirror lens sections including:a first mirror lens section having a first constant radius of curvature,located to one side relative to the width-wise axis of the mirror lens;a second mirror lens section having a second constant radius ofcurvature which is different from the first radius of curvature, locatedto the other side of the width-wise extending axis of the mirror lens;and a third mirror lens section having a third radius of curvature andlocated between the first and second mirror lens sections and occupyingat least part of a middle section of the mirror lens where anintersection of the width-wise extending axis and height-wise extendingaxis is located; wherein the third radius of curvature is a constantradius of curvature, which is larger than the first and second radius ofcurvature; and wherein the mirror lens is thicker in the first andsecond mirror lens sections and thinner in the third mirror lenssection.
 3. An asymmetric mirror comprising: a convex mirror lens havinga periphery which defines at least one substantially width-wiseextending axis, at least one substantially height-wise extending axis, aplurality of sections arranged at least height-wise along the mirrorlens, and a plurality of sections arranged at least width-wise along themirror lens; said plurality of height-wise sections including: a firstheight-wise section having a first height-wise radius of curvature,located to one side relative to the width-wise axis of the mirror lens;a second height-wise section having a second height-wise radius ofcurvature which is different from the first height-wise radius ofcurvature, located to the other side of the width-wise extending axis ofthe mirror lens; and a third height-wise section having a thirdheight-wise radius of curvature and located between the first and secondheight-wise sections and occupying at least part of a middle section ofthe mirror lens where an intersection of the width-wise extending axisand height-wise extending axis is located; and said plurality ofwidth-wise sections including: a first width-wise section having a firstwidth-wise radius of curvature, located to one side relative to theheight-wise axis of the mirror lens; a second width-wise section havinga second width-wise radius of curvature which is different from thefirst width-wise radius of curvature, located to the other side of theheight-wise extending axis of the mirror lens; and a third width-wisesection having a third width-wise radius of curvature and locatedbetween the first and second width-wise sections and occupying at leastpart of a middle section of the mirror lens where the intersection ofthe width-wise extending axis and height-wise extending axis is located.4. The mirror of claim 3 wherein the third width-wise radius ofcurvature is a constant radius of curvature, which is larger than thefirst and second width-wise radii of curvature.
 5. The mirror of claim 3wherein the third height-wise radius of curvature is a constant radiusof curvature, which is larger than the first and second height-wiseradii of curvature.
 6. An asymmetric mirror comprising: a convex mirrorlens having a periphery which defines at least one substantiallywidth-wise extending axis and at least one substantially height-wiseextending axis and a plurality of mirror lens sections arranged at leastwidth-wise along the mirror lens, said plurality of mirror lens sectionsincluding: a first mirror lens section having a first radius ofcurvature, located to one side relative to the height-wise axis of themirror lens; a second mirror lens section having a second radius ofcurvature which is different from the first radius of curvature, locatedbetween the first section and the height-wise extending axis of themirror lens; and a third mirror lens section having a third radius ofcurvature which is different from the first radius of curvature, locatedto the other side of the height-wise extending axis of the mirror lens;and a fourth mirror lens section having a fourth radius of curvaturewhich is different from the first radius of curvature, located betweenthe third section and the height-wise extending axis of the mirror lens;and a fifth mirror lens section having a fifth radius of curvature andlocated between the second and fourth sections and occupying at leastpart of a middle section of the mirror lens where an intersection of thewidth-wise extending axis and height-wise extending axis is located, anda sixth mirror lens section having a changing radius of curvaturelocated between the first mirror lens section and the second mirror lenssection; and a seventh mirror lens section having a changing radius ofcurvature located between the second mirror lens section and the fifthmirror lens section; and an eighth mirror lens section having a changingradius of curvature located between the fifth mirror lens section andthe fourth mirror lens section; and a ninth mirror lens section having achanging radius of curvature located between the fourth mirror lenssection and the third mirror lens section.
 7. The mirror of claim 6wherein the first, second, third, fourth and fifth radii of curvatureare constant radii of curvature.
 8. The mirror of claim 6 wherein thefifth mirror lens section has a larger radius of curvature than thefirst, second, third, fourth, sixth, seventh, eighth, and ninth radii ofcurvature.
 9. The mirror of claim 6 wherein the mirror lens is thickerin at least one of the plurality of mirror lens sections with respect toa remainder of the plurality of mirror lens sections.
 10. The mirror ofclaim 6 wherein the mirror lens is thinner in at least one of theplurality of mirror lens sections with respect to a remainder of theplurality of mirror lens sections.
 11. The mirror of claim 6 wherein themirror lens is thinnest in the fifth mirror lens section.
 12. The mirrorof claim 6 wherein the mirror lens is thickest in the fifth mirror lenssection.
 13. An asymmetric mirror comprising a convex mirror lens havinga periphery which defines at least one substantially width-wiseextending axis and at least one substantially height-wise extendingaxis, a mirror back for supporting the mirror lens and a mirror rim forattaching the mirror lens to the mirror back, wherein the mirror rimincludes a plurality of rim sections, at least one of which is thinnerthan a remainder of the plurality of rim sections, a plurality of mirrorlens sections of constant radius of curvature arranged at leastwidth-wise along the mirror lens, said plurality of mirror lens sectionsincluding: a first mirror lens section having a first constant radius ofcurvature, located to one side relative to the height-wise axis of themirror lens; a second mirror lens section having a second constantradius of curvature which is different from the first radius ofcurvature, located to the other side of the height-wise extending axisof the mirror lens; and a third mirror lens section having a thirdradius of curvature and located between the first and second mirror lenssections and occupying at least part of a middle section of the mirrorlens where an intersection of the width-wise extending axis andheight-wise extending axis is located; wherein the third radius ofcurvature is a constant radius of curvature, which is larger than thefirst and second radius of curvature.
 14. An asymmetric mirrorcomprising: a convex mirror lens having a periphery which defines atleast one substantially width-wise extending axis and at least onesubstantially height-wise extending axis, a mirror back for supportingthe mirror lens and a mirror rim for attaching the mirror lens to themirror back, wherein the mirror rim includes a plurality of rimsections, at least one of which is thinner than a remainder of theplurality of rim sections, a plurality of mirror lens sections ofconstant radius of curvature arranged at least height-wise along themirror lens, said plurality of mirror lens sections including: a firstmirror lens section having a first constant radius of curvature, locatedto one side relative to the width-wise axis of the mirror lens; a secondmirror lens section having a second constant radius of curvature whichis different from the first radius of curvature, located to the otherside of the width-wise extending axis of the mirror lens; and a thirdmirror lens section having a third radius of curvature and locatedbetween the first and second mirror lens sections and occupying at leastpart of a middle section of the mirror lens where an intersection of thewidth-wise extending axis and height-wise extending axis is located; andwherein the third radius of curvature is a constant radius of curvature,which is larger than the first and second radius of curvature.
 15. Anasymmetric mirror comprising: a convex mirror lens having a peripherywhich defines at least one substantially width-wise extending axis andat least one substantially height-wise extending axis, wherein theconvex mirror lens is asymmetric with respect to both the width-wiseextending axis and the height-wise extending axis, a plurality of mirrorlens sections of constant radius of curvature arranged at leastwidth-wise along the mirror lens, said plurality of mirror lens sectionsincluding: a first mirror lens section having a first constant radius ofcurvature, located to one side relative to the height-wise axis of themirror lens; a second mirror lens section having a second constantradius of curvature which is different from the first radius ofcurvature, located to the other side of the height-wise extending axisof the mirror lens; and a third mirror lens section having a thirdradius of curvature and located between the first and second mirror lenssections and occupying at least part of a middle section of the mirrorlens where an intersection of the width-wise extending axis andheight-wise extending axis is located; wherein the third radius ofcurvature is a constant radius of curvature, which is larger than thefirst and second radius of curvature.
 16. The mirror of claim 15,further comprising: a mirror back for supporting the mirror lens and amirror mount; wherein the mirror back is capable of accepting aplurality of mounting mechanisms.
 17. The mirror of claim 16 wherein themirror mount is capable of accepting a ball stud mount and a tunnelmount.
 18. The mirror of claim 16 wherein the mirror mount is capable ofaccepting a non-vertical mounting arm.
 19. The mirror of claim 18wherein the mirror mount is capable of accepting a clamp mount, ascrew-clamp mount, and a ball-clamp.
 20. An asymmetric mirrorcomprising: a convex mirror lens having a periphery which defines atleast one substantially width-wise extending axis and at least onesubstantially height-wise extending axis, wherein the convex mirror lensdefines a base with a peripheral edge lying in a flat plane, and theperipheral edge of the base asymmetrically shaped which is neithercircular, nor oval, nor elliptical in shape and is asymmetric withrespect to both the width-wise extending axis and the height-wiseextending axis, a plurality of mirror lens sections of constant radiusof curvature arranged at least width-wise along the mirror lens, saidplurality of mirror lens sections including: a first mirror lens sectionhaving a first constant radius of curvature, located to one siderelative to the height-wise axis of the mirror lens; a second mirrorlens section having a second constant radius of curvature which isdifferent from the first radius of curvature, located to the other sideof the height-wise extending axis of the mirror lens; and a third mirrorlens section having a third radius of curvature and located between thefirst and second mirror lens sections and occupying at least part of amiddle section of the mirror lens where an intersection of thewidth-wise extending axis and height-wise extending axis is located; andwherein the third radius of curvature is a constant radius of curvature,which is larger than the first and second radius of curvature.
 21. Themirror of claim 20, further comprising: a mirror back for supporting themirror lens and a mirror mount; wherein the mirror back is capable ofaccepting a plurality of mounting mechanisms.
 22. The mirror of claim 21wherein the mirror mount is capable of accepting a ball stud mount and atunnel mount.
 23. The mirror of claim 21 wherein the mirror mount iscapable of accepting a non-vertical mounting arm.
 24. The mirror ofclaim 23 wherein the mirror mount is capable of accepting a clamp mount,a screw-clamp mount, and a ball-clamp.
 25. An asymmetric mirrorcomprising: a convex mirror lens having a periphery which defines atleast one substantially width-wise extending axis and at least onesubstantially height-wise extending axis, wherein the convex mirror lensis asymmetric with respect to both the width-wise extending axis and theheight-wise extending axis, a plurality of mirror lens sections ofconstant radius of curvature arranged at least height-wise along themirror lens, said plurality of mirror lens sections including: a firstmirror lens section having a first constant radius of curvature, locatedto one side relative to the width-wise axis of the mirror lens; a secondmirror lens section having a second constant radius of curvature whichis different from the first radius of curvature, located to the otherside of the width-wise extending axis of the mirror lens; a third mirrorlens section having a third radius of curvature and located between thefirst and second mirror lens sections and occupying at least part of amiddle section of the mirror lens where an intersection of thewidth-wise extending axis and height-wise extending axis is located;wherein the third radius of curvature is a constant radius of curvature,which is larger than the first and second radius of curvature.
 26. Themirror of claim 25, further comprising: a mirror back for supporting themirror lens and a mirror mount; wherein the mirror back is capable ofaccepting a plurality of mounting mechanisms.
 27. The mirror of claim26, wherein the mirror mount is capable of accepting a ball stud mountand a tunnel mount.
 28. The mirror of claim 26, wherein the mirror mountis capable of accepting a non-vertical mounting arm.
 29. The mirror ofclaim 28, wherein the mirror mount is capable of accepting a clampmount, a screw-clamp mount, and a ball-clamp.
 30. An asymmetric mirrorcomprising: a convex mirror lens having a periphery which defines atleast one substantially width-wise extending axis and at least onesubstantially height-wise extending axis, wherein the convex mirror lensdefines a base with a peripheral edge lying in a flat plane, and theperipheral edge of the base asymmetrically shaped which is neithercircular, nor oval, nor elliptical in shape and is asymmetric withrespect to both the width-wise extending axis and the height-wiseextending axis, a plurality of mirror lens sections of constant radiusof curvature arranged at least height-wise along the mirror lens, saidplurality of mirror lens sections including: a first mirror lens sectionhaving a first constant radius of curvature, located to one siderelative to the width-wise axis of the mirror lens; a second mirror lenssection having a second constant radius of curvature which is differentfrom the first radius of curvature, located to the other side of thewidth-wise extending axis of the mirror lens; and a third mirror lenssection having a third radius of curvature and located between the firstand second mirror lens sections and occupying at least part of a middlesection of the mirror lens where an intersection of the width-wiseextending axis and height-wise extending axis is located; wherein thethird radius of curvature is a constant radius of curvature, which islarger than the first and second radius of curvature.
 31. The mirror ofclaim 30, further comprising: a mirror back for supporting the mirrorlens and a mirror mount; wherein the mirror back is capable of acceptinga plurality of mounting mechanisms.
 32. The mirror of claim 31, whereinthe mirror mount is capable of accepting a ball stud mount and a tunnelmount.
 33. The mirror of claim 31, wherein the mirror mount is capableof accepting a non-vertical mounting arm.
 34. The mirror of claim 33,wherein the mirror mount is capable of accepting a clamp mount, ascrew-clamp mount, and a ball-clamp.